Sheet-metal door and analogous structure.



PATENTED JUNE 30, 1908.

T. I. DUFFY. SHEET METAL-DOOR AND ANALOGOUS STRUGTURE.

APPLICATION FILED JUNE 29, 1905.

2 SHEETS-SHEET l.

PATENTED JUNE 30, 1908.

T. I. DUFFY. SHEET METAL DOOR AND ANALOGOUS STRUCTURE.

APPLICATION FILED JUNE 29, 1905.

2 SHEETS-SHEET 2.

-f %J40 2y azM/waifi was THOMAS I. DUFFY, OF CHICAGO, ILLINOIS, ASSIGNOR TO VOIGTMANN & COMPANY,

OF CHICAGO, ILLINOIS, A COPARTNERSHIP.

SHEET-METAL DOOR AND ANALOGOUS STRUCTURE.

Specification of Letters Patent.

Patented June 30, 1908.

Application filed June 29, 1905. Serial No. 267,537.

To all whom it may concern:

Be it known that I, THOMAS I. DUFFY, a citizen of the United States, residing at'Ohicago, in the county of Cook and State of Illinois, have invented certain new and useful Improvements in Sheet-Metal Doors and Analogous Structures, of which the following is a specification.

ThlS invention relates to improvements in sheet metal doors of that type wherein the several stiles, panels, etc., of a door or analogous structure, are made of wood or the like provided with a sheathing of sheet metal.

Among the salient objects of the invention are to provide a fireproof structure, the joints and other unions of which will withstand very hi h'temperature without destruction of the cor; to provide in such a device a construction which enables a door to be built up with a variable number of panels without involving the necessity of a difierent type of construction; to provide a construction which when assembled presents an extremely neat and ornamental ap earance and which so nearly conforms to the conventional a pearance of wooden doors that it may e readily painted and grained to imitate the latter; to provide a construction the parts of which when assembled are interlocked with each other by means of a peculiar locking mechanism practically concealed from view; to provide a construction which lends itself to economical manufacture by means of dies and forming machines; and in general to provide an improved construction of the character referred to.

To the above ends the invention consists in the matters hereinafter described and more (particularly (pointed out in the a pende claims, an the invention will e readily understood from the following descriptlon, reference being had to the accompanying drawings, in which- Flgure 1 is an elevation or face view of one side of a door embodying m invention; Fi 2 is an inside edge view 0 one of the si e stile members, the upper end portion being broken away to reduce the length of the fig ure; Fig. 3 1s an end view of the stile; Fig. 4 is a plan view of the end portion of the sheet metal covering which folds about and incloses the end of the stile shown in Fig. 3; Fig. 5 is a fragmentary portion of one corner of the door shown on a larger scale than that of Fig.

1, the inter'fitting of the end rail and stiles and the locking mechanism being shown in dotted lines; Fig. 6 is an outer edge view of the part shown in Fig. 5; Fig. 7 is a sectional view taken on line 77 of Fig. 5; Fig. 8 is a sectional view taken on line 88 of Fig. 5; Fig. 9 is a detail tenon portion of one of the end stiles; Fi 10 is an end view of the same; Fig. 11 is a an view of a reinforcing plate which underlies the end folds of the sheet metal which incloses the end of the stile shown in Fig. 10; Fig. 12 is a fragmentary end portion of the blank of sheet metal which forms the end covering of the stile shown in Figs. 9 and 10.

In carrying out the present invention one of the objects aimed at is to employ stile members, cross rails and panels which closely conform to the conventional corresponding parts of an ordinary wooden door and to cover these members in such manner as to produce sharp, clean cut angles, miters, etc., so that the finished door very closely resembles in ap earance an ordinary wooden door and may e ainted and grained to exactly imitate the atter. At the same time the main object, to wit, the production of a fireproof door, is not departed from. In carry- 111 out the invention in a preferred form the side stile members, as 1, 2, are grooved throughout their lengths at their inner edges, as indicated at 3, Fig. 2, to a suitable depth to receive the correspondingly tenoned edges of the panels 4; the tenons 5 (see Fig. 8) of the anels being preferably arranged to extend into these grooves 3 practically the full de th of thelatter Eachside stileis also provi ed at each end with a mortise 6 of suitable depth and width to receive a correspondingly shaped tenon 7 formed upon the opposite ends of the upper and lower end rails '8 and 9, res ectivel Similarly the side stiles are provi ed wit 1 intermediate mortises to receive correspondin tenons upon the cross rails 11 of the door; t ese latter mortises and tenonsbeing precisely like that shown and described in F lgs. 5, 8 and 9 and accordingly not illustrated. The end shoulders 12 of the end rails andintermediate cross rails are preferably s uare shoulders formed at right angles to t e tenons which extend beyond the same, as seen clearly in Figs. 8 and 9, so that said shoulders 12 abut squarely against the inner edges of the side stlles when the parts are assembled. The inner edges of the end rails 8 and 9 and both edges of the cross rails 11 are grooved to receive the edges of the panels in precisely the same manner as are the side stiles 1 and 2, and the panels 4 are provided with the tenons 5 extending around their entire circumference.

\Vith the filling members of the door thus constructed, the metal sheathing is constructed and applied as follows: a strip of sheet metal 13 wide enough to inclose the outer edge, both sides and the inner edge, and to fold downwardly into the groove 3 of the stile (see Fig. 8) is provided, and the end margins thereof cut into shape, as indicated in Fig. 4,to fold over and upon the end margins of the stile. By means of a suitable machine I first fold a metal covering about the sides and edges of the stile and force the lateral edges of the covering into the groove 3, without in this operation bending the end folds. This operation may be conveniently performed by means of suitable bending rollers through which the stile passed longitudinally, thus insuring a umform cross sectional finish throughout the length of the stile and forming extremely smooth, clean and accurate angles. The end folds are next formed by means of suitable tools; the tongue ortion 14, which it will be noted is of a wi th corresponding to.the'

thickness of the stile (seeFig. 3), and the two smaller tongues 15 being first bent down against the end of the stile. The main flaps 16 are next folded over along the dotted lines 17 at right angles to the main body of the flaps, and the latter again folded along the lines 18 so as to lie against the end of the stile in the position best indicated at'the lower end of Fig. 2; the edges of the flaps 16 lying outside of the lines 17 being inserted in a saw-kerf 19 which has previously been formed in the end of the stile. The end of the stile as thus finally inclosed presents the appearance seen in Fig. 3 in which it will be noted that the end is entirely covered and all external angles of the stile complete and smooth.

The end rails 8 and 9 are first inclosed with a sheathing 20 in substantially the same manner as are the side stiles 1 and 2 with the exception that the end folds are modified somewhat so as to not interfere with the tenons of these rails and also to avoid having the folds overlap each other at any point and thus roduce a double thickness, which would inter ere with the accurate fitting of the end shoulders against the edges of the side stiles. To this end the flaps (see Figs. 10 and 12) 21, 22 and 23 are of less width than those of the previously described construction and are so shaped that their edges when they are folded into place meet each other miter-fashion, as seen clearly in Fig. 10. Since these flaps do not overlap each other it is immaterial which precede the others in the order of folding, and for that matter they may-all be folded mto position simultaneously. Before folddown, and its object is to insure extremely sharp, clean cut right angles or corners where the sheathing is bent over the end shoulders; the edgesof this plate to lie flush with the sides of the stile serving as a reinforcement over which the sheathing is bent.

In order to lock the rails and side stiles together I provide a specially constructed lock.- ing mechanism forming one feature of the present invention. Describing said construction, 26 designates suitable apertures formed through each of the tenons 7, and within these respective apertures are seated nuts 27. These nuts 27 conveniently take the form of ordinary hex nut blanks, in one edge of each of which is formed a threaded a erture 28 adapted to receive the end of a t readed screw bolt 29. Through the outer portion of the side stile and through the central portion of the tenon are formed bolt apertures which register with the aperture 28 formed in the nut 27 and receive the screw bolt 29; the bolt-head being countersunk as indicated at 30 so that it lies'flush with the outer face of the stile. The threaded bolts, as clearly shown in Fig. 8, are inserted through the outer sheathing and I preferably reinforce the countersunk portion of this sheathing by an underlying washer 31 which is, of course, set into the stile before the latter lS sheathed. This construction enables me to draw the arts together under great pressure without epressing that portion of the stile surrounding the bolt-head. The exterior angles of the hex nut blank enables the latter to be seated accurately in the round aperture, and the presence of the central aperture of the nut blank facilitates the formation of the threaded aperture extending through its side. Of course, it is not essential to use this precise form of nut.

The intermediate cross rails are constructed substantially like the end rail so far as the tenon connections are concerned, and are similarly united to the side stiles by my improved boltand nut locking mechanism.

The panels preferably consist of rectangles of uniform thickness throughout, as best shown in Fig. 7, the opposite sides of-which are covered with metal sheathing 32. Preferably the sheathing is applied by simply crimping the edges over the edges of the anel around the entirecircumference of the atter the corners of the sheathing being cut so that the crimped over edges do not overlap at the corners. The opposite halves of the sheathing are sufficiently held to the panel by the crimping over of the edges and with-- out uniting them to each other; it being noted that when the panel is assembled in the door all of its edges are embedded in the porresponding grooves of the stiles and cross )ars.

As a further and important feature of the present invention I 1provide a special form of metal molding or llet for the angles between the tenons and the inner margins of the stiles and cross bars. This molding is formed of sheet metal and, as clearly shown in Fig. 5, comprises a hollow body portion 33 constructed to rest in the angle between the face ofthe moldin and inner edge of the stile or cross bar w1th its open side towards the anel and an extension portion 34, whicfi takes the form of a web or flange, extended into the oove of the stile or cross bar alongside of t e panel and at its extreme inner edge turned at right angles, as indicated at 35, so as to hook underneath the edge of the panel. The outer configuration of this fillet or molding may, of course, be varied,.but in any event it is so constructed that the outer edge of the metal which forms the molding is turned inwardly against the panel or so shaped as to be concealed. At the corners of the panels the meeting ends of these molding strips are mitered so as to fit together after the usual fashion. The construction of the molding is such that it can be placed in position as the arts of the door are bein assembled, an when the door is assemb ed and the parts locked together the molding is, of course, immovably secured in place.

In assembling a door embodying my preferred construction herein described the several cross rails and two end rails may first be secured to one of the side stiles, the several panels and their moldings next as sembled in place between the end rails and cross rails and the remaining side stile thereafter placed in position u on the tenons and locked thereto in an o vious manner. The structure when completed presents a finished appearance throughout; the joints are all smooth and fireproof and the means of uniting the several parts are entirely concealed except that the heads of the screwbolts 29 are accessible at the edges of the side stiles although flush with the surfaces of the latter.

While I have herein described the locking mechanism whereby the rails and stiles are united as' embodied in the door structure, yet-it will be obvious that the same construction may be embodied in other carpentr constructions, for example, I contemp ate the use of the same construction where partitions are composed of paneled frames; the uprights in such constructions bein inefiect the stiles and the cross bars in e ect the cross rails. Accordingly I do not limit myself to the precise details of construction herein shown except in so far as they are made the subject of detailed claims.

, I claim as my invention:

1. In a sheet metal covered door or analogous structure, a stile member provided with ing the stile, the longitudinal edges of sald covering being turned into and concealed within a groove extending longitudinally throughout the length of the stile in the inner edge thereof and the end margins of said covering consisting of a series of flaps, inserted and concealed m grooves traverslng the end margins of the stile.

2. In a sheet metal covered door or analogous structure, a stile member provided with a sheet metal covering substantially inclosing the stile, the side margins of the metal covering being inserted and concealed within a groove extending longitudinally along the inner edge of the stile, the end margins of the covering being folded across the end margins of the stile and the mar ins thereof inserted in a kerf-like groove suhstantially occupied by said edges and said covering being provided with flaps extending from the outer and inner lateral edges of the stile, respectively, across the end margins thereof and underlying said end folds.

3. In a sheet metal covered door or analogous structure, the combination of a marginal frame comprising side stiles and upper and lower end rail members, each of the members composing said frame having a sheet metal coverin the lateral edges of which terminate an are concealed within grooves formed in the inner edges of the respective frame members and one or more panels provided with sheet metal covering the edges of which terminate at the mar ins of the anels, the margins of said paneI or panels fieing seated in the grooves of the respective marginal frame members, whereby a completely inclosed sheet metal covered structure is formed having the edges of the metal covering concealed as to all its parts.

4. In a sheet metal covered structure, the combinationwith a mortised frame member provided with a sheet metal covering over that art of the frame member forming should ers surrounding the mortise, of a connected frame member provided with a tenon fitting the mortise, shoulders at the base of the tenon, a sheet metal covering over said latter shoulders and an underlying reinforcement ofhard sheet material, whereby sharp abrupt angles are formed at the outer margins of the shoulders of the tenon member adapted to fit accuratel against the cooperating shoulders aroun the mortise of the other member.

5. In a sheet metal covered structure comprising an outer marginal frame and an inner panel, the margins of which are seated in a single piece sheet metal covering env'eloprecesses formed in the inner edges of the outer frame member, the combination with said marginal frame and panel members, of a metal fillet occupying the angle at the intersection of the panel and frame members, said fillet being rovided with a flange-like extension exten ing into the groove of the marginal frame member alongside of the tongue of the panel and held-in place thereby.

6. In a sheet metal covered structure comprising an outer marginal frame andan inner .panel, the margins of which are seated in -grooves formed in the inner edges of the outer frame member, the combination with said marginal frame and panel members of a sheet metal fillet occupying the angle at the intersection of the panel and frame members, said fillet being rovided with a flange-like extension exten 'ng into the groove of the marginal frame member alongside of the panel and terminating in an angular lip ooked underneath the margin of the panel. 7. In a sheet metal covered structure com- 'prisin a mortised frame member, the mortise 0 which extends transversely into one edge of but not through said frame member, and a tenoned member having a tenon adapted to said mortise and a shoulder limiting the extent of insertion of the tenon, the

combination of a lateral margins tig itly seated in a round recess or aperture formed to extend transversely into or through the-body of the tenon and provided also in its lateral edge with a threaded bolt aperture, and a screw-bolt excomprising a screw bolt inserted in one of said members and having screw threaded engagement with the lateral edge of a nut rigidly seated in the other member, the head of said bolt. being countersunk into the sheet metal covering of the structure and an underlying washer-like reinforcement beneath said countersunk bolt, substantially as described.

THOMAS I. DUFFY.

Witnesses EMILIE Rosa, K. A. OosTELLo.

olygonal nut having its 

